Limp Mode Issue

[ejabrod]

Hi Guys,

Recently I had an issue with my '03 (facelift) D4D Avensis.

The turbo was shot and I replaced it. On the 1st motorway drive on the new turbo the waste gate actuator rod snapped and the car went into limp mode at 80mph on the motorway.

I drove for about a week without realising the rod had actually snapped. (thought it was a boost leak from a split pipe or something).

When I realised what it was, I replaced the actuator with the actuator from the old turbo. All seemed to be fine until the car went into limp mode again on the motorway at 80mph.

My mechanic feels that it may be a sensor (vcv - vacum sensor?) Can anyone tell me the correct name of this sensor please? the part numbers are : Toyota 25819-27050 (Denso 139700-0850) so going to try that next

(second pic in this listing http://www.ebay.ie/itm/Toyota-Avensis-T25-2-0-D-4D-Saloon-INTERCOOLER-CONNECTING-PIPE-HOSE-03-08-/331346967602?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item4d25d17c32)

There is a hesitation in 1st and second gear when going up through the revs and almost like there is some kind of 'blockage', a puff of black smoke and hesitation is gone!

Any info/advice appreciated

[FROSTYBALLS]

Topic moved to the Avensis club as requested.

[ejabrod]

thank you :)

[avensisd4d786]

I have never had to replace one, is there any engine lights on?

the name in the parts catalogue is

25819 - VALVE ASSY, VACUUM REGULATING

others describe it as;

VACUUM VALVE SOLENOID

Toyota Avensis EGR Solenoid Vacuum Valve Presure Sensor

did your mechanic say its common for that sensor to go? do you know why your mechanic thinks it that.

[ejabrod]

There is no CEL...the car simply goes into limp mode on the motorway. I had this at low speeds around town when the original turbo was gone (the turbo was well gone - a LOT of lateral movement in the shaft). Would not rev above 1600 rpm.

Due to the fact that I have replaced the turbo and the vac hoses he feels that the other thing that may be causing limp mode is the sensor. His reasoning is : if the turbo is good, there is no boost leak (did a leak down test) and the fact that the issue is intermittant (and happens in a certain geographic location - down a hill) the sensor may be malfunctioning.

It's a bit strange as I drive 80 miles to work in the morning and that's when the car goes into limp mode (80 mph and will not increase power - 2600 rpm - that's it) It happens at the same location each time! (weird I know). I pull into the next available area and turn off the engine. Turn the engine back on and all is fine.

The drive home (same motorway) this does not happen!? The only differnece is there is no downward incline on the journey home.

[frankie406]

Possibly a dirty fuel filter or suction control valve?

[ejabrod]

Possibly a dirty fuel filter or suction control valve?

I will change the fuel filter this weekend.

When you say suction control valve are you referring to the sensor I showed in my 1st post or is it another valve? If so where is it located?

Thanks

[geoweb2k14]

Its not your fuel filter. I had this exact same problem with my 2005 d4d avensis. It turned out to be a broken wire (yellow one)on the electrical connector that connects onto the throttle body. The loom is so tight that there is a constant pull on it. Soldered a bit extra onto mine and its going fine ever since. This is a common problem with this early model. Hope this helps and keep me posted.

George.

[ejabrod]

Thanks for the reply George.

I'm hoping it something like this. Today on the motorway the car did not go into limp mode. This is the 1st time in two weeks and the only difference is that due to now having a toll tag, the car did not come to a complete stop at the toll booth.

I'm not sure if this is related but there is a hesitation in 1st and 2nd gear followed by a big puff of black smoke and in 3rd,4th and 5th there is no hesitation.

Also at very low speed this morning the car went into limp mode....I wasn't in boost.....

[avensisd4d786]

Its not your fuel filter. I had this exact same problem with my 2005 d4d avensis. It turned out to be a broken wire (yellow one)on the electrical connector that connects onto the throttle body. The loom is so tight that there is a constant pull on it. Soldered a bit extra onto mine and its going fine ever since. This is a common problem with this early model. Hope this helps and keep me posted.

George.

Good knowledge. is there any other common faults that you can share.

[avensisd4d786]

this pdf may help with the vac solenoid.

EMISSION CONTROL.pdf

[ejabrod]

Thanks avensisd4d786.

I have an update on this issue - it appears to be no longer happening!! (confused.com) :g:

Have made 2 changes, will write a proper post when I get a minute tomorrow

[avensisd4d786]

I look forward to reading it :)

[ejabrod]

Ok, so a little background:

I drive 150 miles every day to/from work and pass through a toll booth. After the toll there is a slight slope into a sweeping bend and the car was always going into limp mode on this bend.

Up until last week I was coming to a complete stop at the toll booth. I got a toll tag, which means that I can continue at about 40mph through the toll.

Also the wiring leading to the plug I referred to in my 1st post was not tied down. I cable tied the wires to the plug (pics to follow)

Since I got the toll tag and tied the wires, the car has not gone into limp mode.

Is this a coincidence ? I don't know...I will keep this thread updated

[ejabrod]

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[avensisd4d786]

Can someone explain what this solenoid does exactly?

what's with the rubber thing at the bottom.

[ejabrod]

AFAIK, it's a pressure sensor, set to s certsin bar or psi.

It has inlet and outlet hoses. Inward pressure is measured and if within preset range the outlet hose will force air to the wastegate actuator to open it to reveive excess pressure in the turbo.

If the pressure is above to preset level a signal is sent to the ECU to inform of the over boost condition and in turn the ECU enteres the car into limp mode to minimise any damage to the engine.

This is my understanding but I am completely open to correction (as I may have this backward :O )

Also, I do not know what the rubber bung is for.

[DOG7]

Have you checked the EGR valve. I had same prob., I put on a new one , no probs., since then.

Sent from my iPhone using Toyota OC

[ejabrod]

Yeah, I've remover the EGR and cleaned it out completely. The solonoid wasn't sticking but there was a little carbon build up. I may end up blanking it altogether

[DOG7]

The only other that comes to mind .i had limp mode prob , took to Mr T & they said its was an injector prob so I changed the no1 injector which was causing the problem. It was fine after that . That was at 100k, now the car has done 176k now . Just the EGR I mentioned earlier .

Sent from my iPhone using Toyota OC

[ejabrod]

Thank for that DOG7,

I do have a slight hesitation in 1st and 2nd gears under load.

Was thinking there may be an injector problem as well but as the hesitation is very slight and intermittant, I'm gonna leave it for now.

I dont have the software to recode injectors and cannot be without the car for a week if I send my injector away (and there is no guarantee that, if mine is damaged, I could get the same injector back (not requiring a recode))

[ejabrod]

Ah well, the old limp mode is back.

Again on the motorway (but in a different location this time)

Getting annoyed with it now.

Would an injector cause the car to enter limp mode?

[geoweb2k14]

I hear you, did you check the main electrical connect or onto the throttle body? The wording loom on the avensis is very tight (common avensis problem) and the wire tend to break. My car kept going into limp mode and this was the problem. I bought a loom from a scrap yard and joined the wires with connectors and car is running a dream since. Hope this helps you.

[ejabrod]

I didn't yet geoweb.

I'm getting to the end of my tether with this car now :censor:

[DOG7]

Does it happen before or after the thermostat opens, on my car it was after and it was the EGR valve . Before it will be the injector . In my opinion . Take to Mr T and let them check it , it cost about £40 but will know what causing your problem.

Sent from my iPhone using Toyota OC